Modular type terminal block



April 18, 1967 s BRlNSER ETAL 3,315,219

MODULAR TYPE TERMINAL BLOCK 2 Sheets-Sheet 1 Filed July 15, 1964 April 18, 1967 s. B. BRINSER L 3,315,219

MODULAR TYPE TERMINAL BLOCK Filed July 13, 1964 2 Sheets-Sheet 2 United States Patent ,0

3,315,219 MODULAR TYPE TERMINAL BLOCK Stanley Byron Brinser, Steelton, and Charles Henry Fernald, Lancaster, Pa., assignors to AMP Incorporated, Harrisburg, Pa.

Filed July 13, 1964, Ser. No. 382,074 3 Claims. (Cl. 339-198) This invention relates to modular terminal blocks of the type intended to receive terminal tabs on the ends of wires.

An object of the invention is to provide an improved modular-type terminal block. A further object is to provide a terminal block of simplified construction. A further object is to provide a modular-type terminal block which can be adapted to make common electrical connections among varying numbers of conductors. A further object is to provide a terminal block which is not subject to damage during abusive handling.

These and other objects of the invention are achieved in a preferred embodiment comprising an insulating housing having a plurality of metallic receptacles therein. Each receptacle has a generally I-shaped cross-section comprising a relatively Wide strip of conductive metal having its opposite side folded inwardly towards each other to form a double metal thickness web. The sides of the receptacle are flattened to form the flanges of the generally I-shaped cross-section and slots, adapted to receive terminal tabs, are provided in the flanges so that upon insertion of the tabs, they are received between the two layers or thicknesses of metal of the web. The housing has an hour-glass shaped cavity therein in which the receptacles are fitted with the web portions of the receptacls extending through the neck portion of the cavity. The arrangement is such that when terminal tabs are inserted through openings in the housing, thence through slots in the receptacles, the free ends of the receptacle are biased outwardly but are contained within the confines of the neck portion of the cavity so that overstressing of the receptacle is not possible.

In the drawing:

FIGURE 1 is a perspective view, partly in section, showing a group of terminal blocks in accordance with the invention mounted on a track member;

FIGURE 2 is a perspective exploded view showing a strip of receptacles and showing the cross-section of an insulating block;

FIGURE 3 is a sectional view of one block taken along the lines 3-3 of FIGURE 1 and including a terminal;

FIGURE 4 is a view similar to FIGURE 3 but showing a terminal tab inserted into the receptacle; and

FIGURE 5 is a perspective view of a spacer which may be used to separate groups of receptacles contained within an insulating housing in accordance with the invention.

Referring to FIGURES 1 and 2, a terminal block 2 in accordance with the invention is a generally rectangular shape and has divergent feet 4 on its lower end which are received within the sides of a channel-shaped track 6. In normal usage, a plurality of modules are arranged within the channel and are clamped in position by means of suitable clamps 8 which bear against the end modules and against the floor of the channel 6.

The insulating housing within which the receptacles are mounted is relatively tall and has narrow sides 10 which face laterally of the axis of the row of modules and relatively wide sides 12. A vertical column of generally rectangular openings 14 is provided in the narrow sides 10 of the housing to permit the insertion of terminal tabs as described below. It is desirable to provide a detent and lug means 54, 56 on the wide sides of the housings so that the individual modules of the row may be snapped together when an assembly comprising a plurality of modules is made.

The individual receptacles 16 are of a suitable conductive metal such as copper or Phosphor-bronze and comprise a relatively wide strip of such metal having the opposite ends folded inwardly towards each other and having the folded portions flattened or formed to produce a receptacle having a generally I-shaped cross-section. Thus, the web portion of the receptacle comprises a section 18 which is integral with each of the flanges and a pair of free ends 30 which overlie the section 18. The web section 18 is outwardly bent at each end 20 then reversely bent at 22 to form a plane surface portion 24 which extends normally of the plane of the web 18. On its opposite side, the flange surface 24 is again reversely bent towards the plane of the web as shown at 26 and is then bent inwardly at 28 to produce the free ends 30. A slot 32 is provided in each of the surfaces 24 of the flanges to permit insertion of a flat terminal tab 44, the position of this slot being such that upon insertion of the tab, it will be received between the opposed surfaces of the web portion 18 and one of the free ends 30. Advantageously, circular openings 34 are provided in the web portion 18 and in the free ends 30 for reception of a hemispherical boss 46 on the surface of the tabs. These openings thus tend to lock the individual tabs within the receptacle after insertion and prevent accidental removal. The terminal tabs 44 are crimped as shown at 48 in a conventional manner onto a wire 50.

The receptacles 16 are advantageously manufactured by conventional stamping and forming methods and are produced in strip form with each receptacle being connected to the next adjacent receptacle by means of a slug 36 extending between the web portions 18. As explained below, several receptacles may be used in connected form where it is desired to form common electrical connections among four or more wires, or the slug 36 may be removed and the receptacles thus severed from each other where it is necessary to form a connection between only two wires. v i

The insulating housing has a vertically extending hourglass shaped cavity therein, this cavity comprising a central constriction or neck portion 40 which extends between the two enlarged chambers 38. The dimensions of a cavity are such that the flanges of the receptacles can be received within the chambers 38 of the cavity and the web portion of the receptacle can be received within the neck portion. The width of this neck portion is sufi'icient to permit the free ends 30 of the receptacles to move away from the flange section 18 when a tab is inserted although this neck portion prevents overstressing of the free end.

When it is desired to assemble a connector in accordance with the invention, one or more receptacles are inserted into the cavity of a housing and a suitable cap piece 41 having an hour-glass-shaped projection on its underside is snapped in place on the open upper end of the housing. If it is desired to have an individual module capable of making a common electrical connection among eight individal wires, it is merely necessary to insert a strip of four integrally connected receptacles into the module. If, on the other hand, it is desired to have one isolated receptacle capable of connecting two wires extending from opposite directions and, in addition, to make a common connection among siX conductors, an individual, separate receptacle is inserted into the housing, an hour-glass-shaped spacer 52 (FIGURE 5) is then dropped into the cavity above the individual receptacle and a strip of three integrally connected receptacles is then placed in the cavity above the spacer. It will be apparent that other possible combinations as regards common connections among wires can be achieved.

Terminal blocks in accordance with the invention can be produced from a minimum number of parts and the parts themselves are of a extremely simple construction so that they can be easily and cheaply manufactured. A significant feature of the invention which permits the usage of an extremely simple receptacle of the type shown in the hour-glass configuration of the cavity in the housing member. The receptacle itself does not contain any means for preventing overstressing of the free ends 30 when a terminal tab is inserted however, when the receptacle is in position within the housing, such overstressing cannot possibly take place because of the fact that these free ends will be disposed within the neck portion 40 of the cavity as shown in FIGURES 3 and 4. Thus if, through carelessness, an attempt is made to insert an oversized probe or terminal tab, it will be found that the tab cannot be inserted further after the free end of the receptacle is moved against one of the opposed sidewalls of the neck portion 40 of the cavity in the housing. The housing itself, of course, should be molded from a relatively firm plastic such as a firm nylon.

Changes in construction will occur to those skilled in the art and various apparently different modifications and embodiments may be made without departing from the scope of the invent-ion. The matter set forth in the foregoing description and accompanying drawings is offered by way of illustration only. The actual scope of the invention is intended to be defined in the following claims.

We claim:

1. A terminal block comprising an insulating housing and a plurality of axially aligned stacked receptacles in said housing, said receptacles each having a generally I-shaped cross-section and comprising a relatively wide strip of conductive metal, two opposite sides of said strip being folded towards each other to form a double metal thickness web with two opposite edges of said strip being opposed to and parallel to each other on one side of said web, the flanges of said I-shaped cross-section being 40 formed at said folds, and slots in said flanges extending in planes parallel to the plane of said web whereby, upon insertion of a terminal tab into one of said slots, the associated folded side is flexed away from the central portion of said web, an hour-glass cavity in said housing, said receptacles being stacked in said cavity with said folded sides of said strip extending into the neck portion of said cavity whereby, said folded sides are prevented from being overstressed upon insertion of said t-ab.

2. A terminal block comprising an insulating housing having a relatively elongated hour-glass-shaped cavity therein and a plurality of terminal receptacles in said cavity, said receptacles each having a substantially I- shaped cross-section comprising a relatively wide strip of conductive metal, the sides of said strip being folded towards each other and against the plane of said strip on the medial portion thereof to form t-he web portion of said I-shaped cross-section, the folds at the sides of said receptacle extending normally of the plane of said web portion to form the flanges of said I-shaped cross-section, said flanges having openings therein to permit insert-ion of terminals, said receptacles being axially aligned within said cavity with said web portions of said receptacles being received Within the neck portion of said cavity, said housing having openings in said receptacles, said neck portion of said cavity preventing over-bending of said folded portions of said receptacles upon insertion of said terminals.

3. A device as set forth in claim 2 wherein at least two adjacent receptacles are integral with each other to form a common receptacle for at least four terminals.

References Cited by the Examiner UNITED STATES PATENTS 2,903,671 9/1959 Dreher et a1. 339-198 2,924,808 2/1960 Hewes et al. 339-198 3,097,906 7/1963 Shannon 339-32 3,120,990 2/1964 Kinkaid 339-258 X 3,173,738 3/1965 Glunt-z 339-198 3,233,209 2/1966 Lazar et al. 339-198 3,246,283 4/1966 Huska 339-198 FOREIGN PATENTS 777,677 6/ 1957 Great Britain.

EDWARD C. ALLEN, Primary Examiner.

ALFRED S. TRASK, Examiner. 

1. A TERMINAL BLOCK COMPRISING AN INSULATING HOUSING AND A PLURALITY OF AXIALLY ALIGNED STACKED RECEPTACLES IN SAID HOUSING, SAID RECEPTACLES EACH HAVING A GENERALLY I-SHAPED CROSS-SECTION AND COMPRISING A RELATIVELY WIDE STRIP OF CONDUCTIVE METAL, TWO OPPOSITE SIDES OF SAID STRIP BEING FOLDED TOWARDS EACH OTHER TO FORM A DOUBLE METAL THICKNESS WEB WITH TWO OPPOSITE EDGES OF SAID STRIP BEING OPPOSED TO AND PARALLEL TO EACH OTHER ON SAID SIDE OF WEB, THE FLANGES OF SAID I-SHAPED CROSS-SECTION BEING FORMED AT SAID FOLDS, AND SLOTS IN SAID FLANGES EXTENDING IN PLANES PARALLEL TO THE PLANE OF SAID WEB WHEREBY, UPON INSERTION OF A TERMINAL TAB INTO ONE OF SAID SLOTS, THE ASSOCIATED FOLDED SIDE IS FLEXED AWAY FROM THE CENTRAL PORTION OF SAID WEB, AN HOUR-GLASS CAVITY IN SAID HOUSING, SAID RECEPTACLES BEING STACKED IN SAID CAVITY WITH SAID FOLDED SIDES OF SAID STRIP EXTENDING INTO THE NECK PORTION OF SAID CAVITY WHEREBY, SAID FOLDED SIDES ARE PREVENTED FROM BEING OVERSTRESSED UPON INSERTION OF SAID TAB. 